Ehs Maintenance Manual
Ehs Maintenance Manual
Ehs Maintenance Manual
The provincial Safety Inspection Audit Program, which started in 1999, serves two
purposes: the safety inspections done by the operator's mechanics are audited and the
operator’s preventive maintenance (PM) program is evaluated. These evaluations have
revealed a wide range of PM programs. Some operators had very comprehensive PM
programs with regular, detailed inspection of all components. Other programs were
limited to “change oil every 5,000 km and fix it if it breaks”. This has led, in more than
one instance, to poor vehicle performance and premature component failure.
Through discussions with operators and mechanics during and after the audits, we have
found that a new level of awareness often leads to a safer, more reliable fleet. Several
operators asked where they could get more information. We saw this as an opportunity
to provide a framework for developing solid PM programs. This manual was compiled in
consultation with a number of operators who have shared their PM programs with us.
Preventive maintenance should be an important part of every ambulance operator’s
written maintenance policy, which is a required component of the ambulance licensing
process. However, use of this manual is not mandatory. It is not a legislated part of the
Alberta ambulance program.
Operators are encouraged to choose which parts of the manual will be implemented.
Please feel free to adopt or adapt the manual to meet local needs. The following
recommended service intervals will work well for most fleets but can be adjusted to meet
local operations:
For additional copies of this manual, write to Emergency Health Services, Alberta Health
and Wellness, 10025 Jasper Ave., Edmonton, AB T5J 1S6.
ii
TABLE OF CONTENTS
Foreword i
Table of Contents ii
Dedication vii
iii
B.7 Differential Oil Level & Condition 5
B.8 Differential Leaks 6
B.9 Crown & Pinion 6
B.10 Tire Pressure 6
B.11 Tire Condition 6
B.12 Rotate Tires & Balance Wheels 6
B.13 Brake Cylinder Seals, Wheel Bearings & Axle Seals 6
B.14 Front Brakes 6
B.15 Rear Brakes 6
B.16 Rotor Thickness, Front & Rear 7
B.17 Brake Drum Thickness & Condition 7
B.18 Brake Lines & Hoses 7
B.19 Parking Brake Operation 7
B.20 Ball Joints/King Pins 7
B.21 Tie Rod Ends 7
B.22 Idler Arm 7
B.23 Pitman Arm 7
B.24 Steering Gear Box 7
B.25 Control Arms & Bushings 8
B.26 Springs, Bushings & Shackles 8
B.27 U-Bolts & Mounting 8
B.28 Frame & Rivets 8
B.29 Differential Stops 8
B.30 Fuel Lines 8
B.31 Fire Extinguisher 8
B.32 Flares, Triangle Reflectors 8
B.33 Torque All Wheel Nuts & Record 8
B.34 Road Test 8
B.35 Retorque Wheels After Road Test 8
B.36 Wheel Alignment 9
B.37 Lug Nuts & Rim Condition 9
B.38 Transmission Service & Adjustment 9
B.39 Transmission Oil Cooler Lines & Fittings 9
B.40 Transmission Internal Wiring 9
B.41 Transmission Linkage 9
B.42 Service Rear Differential 9
B.43 Differential Backlash 9
B.44 Shock Absorbers 10
B.45 Cables (heater, throttle, brake) 10
SECTION C – BODY
iv
C.10 Air Conditioner Operation 11
C.11 Heater Operation 11
C.12 Armrests & Inner Door Panels 11
C.13 Running Boards, Steps & Attachments 11
C.14 Mud Flaps 11
C.15 Attach Oil Change Sticker 11
v
D.33 Air Conditioner, Patient Compartment 15
D.34 Heater, Patient Compartment 15
D.35 Cabinet Lamps 15
D.36 Electric Oxygen 15
D.37 Options 15
D.38 Electrical Overload / Poor Connections 16
CLIMATE CONTROL
OXYGEN SYSTEM
110-VOLT SYSTEM
12-VOLT SYSTEM
vi
MODULAR BODY
INTERIOR OF MODULE
MEDICAL EQUIPMENT
Schedule A 23
Schedule B 24
Schedule C 26
Schedule D 28
vii
DEDICATION
As a part-time ambulance attendant who worked with St. Paul and District Ambulance,
Vern understood the need for fleet safety and reliability. As an emergency vehicle
technician, Vern was a highly trained mechanic who specialized in maintenance and
repair of ambulances and fire apparatus in northeastern Alberta.
His vision, and his passion for the safety of his patients and coworkers, led to the
creation of this manual.
viii
SECTION A – ENGINE COMPARTMENT
A.1 Change Engine Oil
Refer to owner’s manual for recommended oil viscosity. Use of proper viscosity is
especially important due to the severe duty application of ambulances. On the inspection
form, record the number of litres used.
A.5 Belts
Check for worn, cracked or glazed belts. Check that belt tension is set to manufacturer’s
specifications. Check for worn bearings on idlers. It is common for belts to glaze and slip
due to the high load that is demanded from the alternator and accessories. Suggested
belt lifetime is 50,000 km.
A.6 Hoses
Inspect for cracked, deteriorated or brittle hoses. Check for proper and secure routing.
Check for loose or deteriorated clamps. It is important to check for loose hose clamps
regularly as they may loosen due to expanding and contracting of the hoses.
1
A.11 Coolant Level and Condition
Check coolant level; if equipped with an overflow reservoir, ensure that it is full.
Check for any leaks in the cooling system. Check coolant condition to ensure there is
proper lubrication for moving parts. If there is any discoloration, the coolant should be
flushed and replaced.
It is very important to test the alternator with an AVR so that you have an accurate
reading. Due to the high electrical load caused by the ambulance conversion, a failing
alternator will cause the system to start feeding off the batteries. This will result in a
lower voltage and some components will fail to operate correctly.
2
A.18 Fan, End Play and Operation
Ensure there is not excessive endplay in the fan. Due to severe duty application, it is
important to check fan endplay regularly. Check that blades are not damaged and check
fan operation by testing the airflow. This is important to ensure that the engine does not
overheat. The fan shroud must be fully intact to prevent water pump failure. When part of
the fan shroud is damaged or missing, changes in airflow may create an imbalance in
the fan’s operating plane, causing premature fan or water pump failure.
3
A.26 Block Heater Operation
Check block heater cord for cracks, corrosion, damage and plug condition. Test block
heater operation.
A.27 Belts
All belts should be replaced at 50,000 km due to the severe duty application.
Inspect condition of all pulleys. Tighten new belts to manufacturer’s specification.
Recheck the belt tension following the test drive as they may stretch after engine has
been run. The heavy load demand on the alternator causes high load to the belt.
Change them before they break!
A.30 Thermostat
Replace thermostat. Run vehicle to ensure proper operation and temperature. The
thermostat is replaced at this time, due to the severe duty application, in order to
maintain vehicle efficiency and passenger comfort.
A.32 Turbocharger
Check for loose or broken connecting bolts and leaking gaskets on the turbocharger.
Inspect for damaged turbo vanes and loose bushings. High heat within the turbo can
cause gaskets to leak or bushings to wear. These can cause immediate failure.
4
SECTION B – UNDER VEHICLE
B.1 Lube Chassis
Grease ball joints, tie rod ends, idler arm, pitman arm, u-joints and other grease zerks.
Use grease as per manufacturer’s specifications. Inspect all boots for cracks and ensure
all grease zerks take grease.
On units with a two-piece driveshaft, remove the rear u-joint from the differential and
remove the steady bearing bolts. Lower the shaft and steady bearing. Check for seized
u-joints as described above.
It is important to be able to move the u-joints freely because a seized joint might not be
readily noticeable and will fail if not repaired.
B.3 Exhaust
Check for corroded, cracked or leaking exhaust components. Inspect all exhaust
hangers. This is critical to prevent exhaust gases from entering the interior of the vehicle.
5
B.8 Differential Leaks
Check rear pinion seal and differential cover for leaks. Check backing plates on
differential. Look for oil leak at axle seals. Axle seals and pinion seals are a common
place for oil to leak as seals become brittle or wear on axle shafts and pinion yoke. Also,
the differential vent could be plugged, leading to increased pressure within the housing,
which can cause leaks.
6
B.16 Rotor Thickness, Front and Rear, if Equipped
Check that rotor thickness is within manufacturer’s specifications. Record measurements
on inspection form. Rotor thickness is very important due to the severe duty application.
As the rotor becomes thinner, the brakes may not cool correctly causing brake fade.
Check radial run out and ensure wheel bearing does not have excessive play. Radial run
out may cause vehicle instability while braking, as vehicle will shake when the brakes
are applied. Check rotors for excessive grooves on wear surface.
Due to severe duty application, especially when cornering quickly, a lot of stress
is put on front suspension and steering components. This results in more wear,
so the following components need to be checked frequently:
7
B.25 Control Arms and Bushings
Check for damaged or loose control arms and bushings. Check control arms for proper
travel. Refer to B.20.
8
B.36 Wheel Alignment, if Required
Do a wheel alignment if there is any abnormal tire wear or if the vehicle pulls to left or
right. (Rule out faulty steering and suspension components.) Wheel alignment should be
done whenever any front-end components are replaced as this can cause the alignment
to be out of specifications.
In severe duty applications, it is very important to inspect and service the differential at
regular intervals to prevent premature failure. Failures can be caused by worn or loose
bearings, which may not be noticeable while driving.
9
B.44 Shock Absorbers
Disconnect one end of each shock absorber. Inspect for weak, damaged or seized
shocks. This is done to ensure proper operation of vehicle for stability. You may not be
able to determine if a shock is working correctly without removing one end and checking
operation.
SECTION C - BODY
C.1 Clearance Lights
Check lights for proper operation and secure mounting. Check for cracked, damaged or
missing lenses.
C.2 Headlamps
Check the headlamps for proper operation and proper aim. Check for cracked or
damaged lenses. Vehicle vibrations can cause headlamps to loosen, thereby causing
improper aim and poor visibility. If headlamps are replaced, it is good practice to re-aim
them.
10
C.10 Air Conditioner Operation – Record Temperature
With a thermometer, check temperature of cool air at duct outlets for front and rear air
conditioners. Ensure that they are within the manufacturer’s specifications. Record
temperatures on inspection form.
C.15 Attach Oil Change Sticker; Record Date and Odometer Reading
Attach a sticker with date and odometer reading as a reminder of the last and next
scheduled service.
11
D.3 Main Power or Battery Switch, if Equipped
The function of the battery switch is to disconnect all power draws in vehicle. On many
ambulances, power for the on-board computers, including the transmission controller,
may be hooked up to bypass the battery switch. This is to keep the computer chips
programmed and in a constant state of readiness. When testing, identify whether it is
hooked up this way or not. Check to see that the switch is mounted securely. Check
continuity on both sides of the switch to be sure it is making full contact and complete
disconnection. Check operation of isolator module for battery, making sure each circuit is
connecting correctly.
Remove lenses and check wiring, making sure that the wires are not damaged and
insulation is intact. Check ground in the body of light bar and to each light and rotator.
Clean rotators and lubricate with light grease (lubra plate graphite). Make sure lens seals
are good. Clean lenses before installing. Draw test again to compare difference to before
and after servicing.
Ensure mounting brackets and main wire cable to the ambulance are secure. Ensure
that the grommet through the body of ambulance is good and does not leak.
12
D.9 Wig-wag Headlamps
Check operation of wig-wag headlamps. Wig-wags are intended to only work on low
beam headlamps. When high beams are activated, the wig-wag control module should
not flash.
Check wiring and connections to headlamps from wig-wag control. If the control module
is mounted where it is exposed to the outside atmosphere, check it for moisture, rusting
or corrosion.
13
D.18 Back Lighting, Switch Labels
Check the function of back lighting on the front switch console. On newer units, the back
lighting comes on with the park lamps. On some older units, turning on the master switch
or “AMB Connect” switch activates it.
14
PATIENT COMPARTMENT SWITCH CONSOLE
15
D.38 Electrical Overload / Poor Connections
Check wire connections, wiring and ground straps for discoloration, corrosion and dirty
terminals, which can all cause poor connections. Discoloration is also a sign of
overloading causing too much heat. Ensure that the wires are the proper size for the
loads they are carrying and that connectors are the proper size for the wire used.
Check for dry bushings if a motor seems to drag. A draw test may indicate that it needs
to be serviced or replaced.
CLIMATE CONTROL
Set the patient compartment heater to maximum heat. Check temperature with
a thermometer. If the ambulance has a combination heater/air conditioner, set the dash
air conditioning to maximum cooling and the rear heater to maximum heat. Note any
change in the heater's output temperature. Each unit is to be independent of each other.
Changes in one unit should not affect the other.
Check shut off valves, if equipped. Some units have shut off valves on the hoses going
to heater core. Some older units have a push-pull control at the rear panel or under the
dash near the driver. Check cable operation; make sure it is freely moving on both ends.
If not, disconnect cable and determine if the cable or shut off valve is defective. Repair
or replace as necessary.
16
OXYGEN SYSTEM
In some systems the oxygen flow is controlled by a remotely switched electric solenoid.
Be sure the solenoid is turned ON so that the whole system is pressurized.
17
ON-BOARD SUCTION SYSTEM
Check motor and wiring for signs of overheating. Check for loose or corroded wire
terminals and ground straps.
Other suction units use a slide valve and/or a variable speed motor switch to regulate
the amount of vacuum.
110-VOLT SYSTEM
18
D.59 Inverter-powered Outlets
With an AC voltmeter, check the function of each 110-volt outlet supplied by the inverter.
If the voltage varies, check all connections before removing inverter for repairs.
Sometimes loose or corroded connectors can cause voltage fluctuations.
12-VOLT SYSTEM
MODULAR BODY
19
D.69 Exterior Compartments
Check seals on all exterior compartment doors. Check floor and corners for rust or
corrosion. Check for leaks in compartment. Replace seals if needed and repair any
holes in the body of the compartment.
INTERIOR OF MODULE
D.74 Shelving
Check that the mounting strips for adjustable shelves are secure. Check all supports to
ensure that they are attached to the mounts securely.
D.76 Squad Bench and CPR Seat, Lid Latch and Hold-Open Device(s)
Check lid latches to ensure that they lock properly. Check that hinges are securely
attached to the lid and to the bench structure. These checks will ensure nothing can fall
out, in case of a collision or upset. Check lid hold-open device(s) to be sure the mounts
are secure. Check for proper function.
MEDICAL EQUIPMENT
20
D.78 Main Cot, Clean and Lubricate
Clean the main cot as per manufacturer’s specifications. Lubricate all moving parts using
light (white) grease. Check and lubricate the wheel bearings and the pivots on the
wheels.
21
SAMPLE FORMS
22